India’s tyre recycling sector, long plagued by fragmented operations and lax compliance, is undergoing a critical overhaul. With Gujarat’s recent approval for continuous pyrolysis plants, the industry is moving decisively towards cleaner, scalable and regulation-driven solutions. This shift signals more than a technological upgrade and it’s a rebuke of outdated batch systems and a call for formalisation, traceability and environmental accountability. As global demand for sustainable materials rises, India’s pivot positions it as a potential leader in circular economy practices. In conversation with TRRAI President Chetan Joshi, we explore how this development could redefine the future of tyre waste management at home and abroad.

India’s tyre recycling sector is on the cusp of a transformational shift with the Gujarat Pollution Control Board (GPCB) approving the establishment of continuous pyrolysis plants in the state. The move marks a significant departure from traditional batch-based tyre processing systems, promising to boost efficiency, environmental compliance and resource recovery at an industrial scale.

“This shift is nothing short of revolutionary,” said President of the Tyre and Rubber Recyclers Association of India (TRRAI) Chetan Joshi. “We’re moving from outdated, fragmented batch operations to streamlined, automated continuous pyrolysis systems. This is going to uplift the entire industry, from cleaner emissions to higher resource recovery, better traceability and serious investor interest. It sets a new national standard and will accelerate formalisation, industrial-scale operations and a far more sustainable approach across India.”

The approval has been met with optimism by recyclers and environmental advocates alike as it signifies a structural change in how end-of-life tyres will be handled in India, which is home to more than 1.8 million tonnes of tyre waste annually.

The Gujarat model mandates stringent adherence to environmental standards, particularly concerning air quality and emissions. Continuous pyrolysis plants approved under the new framework are required to incorporate top-tier pollution control mechanisms.

“We see compliance not as an obligation but as a core design principle. Our plants are being built with advanced air pollution control devices (APCDs), real-time emissions monitoring and automation that ensures consistent performance. We’re aligning with both GPCB and CPCB regulations through pro-active design, third-party audits and integrating global best practices. It’s not just about meeting today’s standards but staying ahead of tomorrow’s,” said Joshi.

The approach reflects a broader shift in the recycling sector, where regulatory compliance is no longer viewed as a hurdle but as a strategic advantage and market differentiator.

Industrial scale

Under the new directive, each continuous pyrolysis facility must operate at a minimum capacity of 60 tonnes per day (TPD). This scale reflects the government’s push to industrialise tyre recycling and eliminate inefficient, informal practices.

“Scaling to 60 TPD is a serious industrial commitment and it means heavy investment in automation, utilities, safety systems and logistics. But it’s also the only way forward. India generates over 1.8 million tonnes of end-of-life tyres annually. This scale allows us to handle the problem responsibly while creating traceable and economically viable recycling ecosystems,” Joshi said.

With India’s growing automotive base, the urgency to develop sustainable, high-capacity recycling infrastructure has never been higher.

One of the key advantages of continuous pyrolysis lies in its outputs that include valuable petrochemical byproducts like pyrolysis oil, sustainable fuels and recovered carbon black (rCB). These materials are increasingly in demand across a range of industries, from rubber manufacturing to renewable energy.

“These by-products are entering a new phase of global relevance. Recovered carbon black is being adopted in rubber, plastics and even pigments. Pyro oil, when upgraded, is a viable alternative fuel. We’re actively engaging with global buyers and certifiers to standardise and integrate these outputs into international supply chains. The world is ready for sustainable alternatives and it’s up to us to deliver with consistency and quality,” averred Joshi.

India’s entry into this global supply chain positions it not just as a recycler of waste but as a producer of sustainable industrial materials.

Circular economy

TRRAI views this milestone as more than an environmental success. It’s a step towards realising India’s vision of a circular economy, where tyre waste is fully reintegrated into the production cycle.

“We aim to be more than recyclers. We want to be circular economy enablers. That means building systems where tyre waste is traceable from collection to output, where value is recovered and re-injected into the economy. We’re developing collection infrastructure, digital traceability and offtake agreements with industries globally. This is not just about waste; it’s about resource optimisation and environmental stewardship,” Joshi explained.

Such a shift could significantly reduce the country’s carbon footprint while fostering job creation and industrial growth.

Despite the enthusiasm, industry leaders acknowledge that challenges remain, particularly in terms of adoption among legacy operators and infrastructure gaps.

“The biggest challenge is inertia as many operators are still working in the unorganised sector with outdated setups. Then there’s infrastructure as a hurdle as tyre collection networks are underdeveloped in many parts of India. To overcome this, we’re advocating policy changes, investing in reverse logistics and training the workforce. Regulatory clarity and enforcement will be key and we’re working closely with industry associations and government bodies to drive this,” said Joshi.

Stakeholders believe that education, investment and enforcement will be pivotal to ensuring widespread transition to continuous pyrolysis systems.

Global trends

Globally, countries like those in Europe and North America have already adopted advanced tyre recycling technologies. But Joshi believes India has a unique opportunity to leapfrog older systems and build world-class facilities from scratch.

“Europe and North America have a head start, especially in policy frameworks and end-use applications. But India’s opportunity lies in scale and adaptability. We can leapfrog legacy systems and build efficient, tech-driven plants from the ground up. If we get the ecosystem right – collection, compliance and capital – we can set new benchmarks, not just catch up. India could become a global hub for tyre recycling technology,” he said.

The industry’s fast pace of development combined with India’s manufacturing and engineering capabilities could make the country a case study in sustainable industrial transformation.

Innovations in emission reduction

In line with global best practices, TRRAI and its partners are integrating innovations to ensure safety and minimal environmental impact.

“We’re integrating closed-loop systems, AI-driven control logic and multi-stage gas cleaning technology. Real-time emissions data will be available both internally and to regulators. Safety protocols are built into every operational layer, from material feeding to shutdown procedures. We’ve also prioritised workforce training and regular third-party safety audits. The goal is to operate with zero compromise on health or the environment,” Joshi explained.

Such innovations are crucial not only to maintaining regulatory compliance but also to building public and investor confidence.

The entry of advanced technologies is expected to catalyse foreign investment and technical collaboration.

“Our approach is partnership-driven. We’re already working with European and Australian technology providers and are in discussions with institutional investors. We see India as a platform for co-creation, where global IP meets local scale and agility. Through industry associations like TRRAI, we’re building collaborative networks to ensure knowledge sharing, investment facilitation and joint innovation,” Joshi noted.

This strategy could help India become a global innovation hub for recycling technologies applicable across other emerging markets.

The vision

Looking to the long term, the industry’s goals extend far beyond domestic waste management. TRRAI envisions exporting its model to developing nations facing similar challenges.

“Our vision is bold but simple. It is to create a fully circular, scalable and replicable tyre recycling ecosystem. India should not only solve its own tyre waste crisis but become a global model for how emerging markets can tackle resource recovery. We see this model being exported to Southeast Asia, Africa and Latin America. With continuous pyrolysis, India can move from reactive recycling to proactive resource management on a global stage,” Joshi concluded.

As Gujarat lights the way with its approval of continuous pyrolysis plants, India’s tyre recycling sector is poised to become a beacon of innovation and sustainability – one that could shape the future of global recycling practices. n

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HS HYOSUNG has formalised a memorandum of understanding (MoU) with the State Government of San Luis Potosí, with the signing taking place at the World Trade Center Mexico City. The event formed part of the Korea-Mexico Business Forum, held alongside the Korean economic delegation's visit to Mexico.

Attending officials included Marcelo Ebrard, Mexico's Secretary of Economy, and Mario García Valdez, Secretary of Economic Development of San Luis Potosí. The two sides confirmed their shared resolve to back the company's local investment and regional growth. Separately, HS HYOSUNG's leadership met bilaterally with Secretary Ebrard to elaborate on its strategic vision and investment plans.

The agreement sets out a phased expansion of HS HYOSUNG's investments in San Luis Potosí beginning in 2027, with the goal of creating a major advanced materials production hub that bolsters supply for North American and wider global markets. The company's advanced materials span tyre cord, a flagship world-leading product, along with mobility, energy, aerospace and defence applications. Its North American operations, spanning Mexico and the United States, turn out tyre cord, airbag materials and mobility interior components for global leaders such as General Motors and Goodyear, underpinned by a highly dependable global supply chain.

Nak-yang Sung, CEO, HS HYOSUNG ADVANCED MATERIALS, said, “This investment goes beyond establishing a simple manufacturing base – it reflects our strategy to turn Mexico into a pivotal hub connecting North America with global supply networks. We are also committed to strengthening local supply chains and creating high-quality jobs to contribute directly to the region's industrial ecosystem.”

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Kumho Petrochemical Group is steering its business towards research-driven, higher-value outputs as oversupply and soft demand continue to weigh on the worldwide petrochemical sector. The Seoul-based group outlined plans to boost spending on speciality chemicals, sustainable materials and novel production methods, a push intended to lift profits while building a foundation for future expansion.

Underlying the move is a deliberate evolution in the group's identity, from a bulk materials vendor to a provider of technology-backed solutions that address shifting customer requirements and stricter environmental rules. A central element of that effort involves widening the speciality lineup, exemplified by added capacity for solution styrene butadiene rubber, a synthetic rubber that enhances durability, rolling resistance and tread wear in high-performance electric vehicle tyres.

Environmental initiatives form another pillar. Facilities built by the company can trap approximately 76,000 metric tonnes of carbon dioxide each year, while separately developed technology turns recycled acrylonitrile butadiene styrene sourced from scrapped household appliances into automotive-grade interior components that satisfy performance standards and generate fewer emissions than conventional methods. The group has also joined forces with POSCO Future M and BEI on anode-free lithium-metal battery development.

Parallel technology-focused programmes are underway at affiliated units. Kumho P&B Chemicals is formulating water-based epoxy resins that curb volatile organic compound releases while incorporating more bio-based inputs to reduce carbon intensity. Kumho Mitsui Chemicals is advancing bio-based polyurethane systems and electric vehicle materials, alongside debottlenecking work to add 100,000 tonnes of annual methylene diphenyl diisocyanate capacity. Kumho Polychem, meanwhile, is targeting ethylene propylene diene monomer through low-temperature polymerisation paired with energy-efficiency improvements.

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Birla Carbon has confirmed a price increase of up to 15 percent for its Speciality Materials products across Asia, scheduled to take effect on 1 October 2026. The company pointed to significant and sustained rises in feedstock costs, driven partly by ongoing geopolitical instability and disruptions in global feedstock markets, as the reason behind the adjustment.

Although Birla Carbon pursued operational efficiencies, supply chain optimisation and disciplined cost management to soften the impact, the scale and persistence of the cost escalation left a price adjustment unavoidable. The company's sales teams will engage customers directly to explain the details and help them navigate the transition.

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ACE Laboratories, an independent ISO/IEC 17025-accredited polymer testing laboratory, has partnered with Abdallah Consulting, LLC, a prominent tyre pyrolysis advisory firm, to introduce VericarbSM. This independent certification programme verifies that materials marketed as recovered carbon black (rCB) meet established criteria for rCB.

Recovered carbon black, derived from end-of-life tyres via pyrolysis, serves as a sustainable substitute for virgin carbon black in rubber and polymer applications. However, the emerging market has lacked the standardisation and independent verification that established supply chains provide. VericarbSM addresses this gap through independent material characterisation and rubber performance data, offering stakeholders a consistent basis for evaluating rCB products.

For producers, certification accelerates market entry and improves buyer approval rates. Consumers gain more capable suppliers and reduced evaluation time, while investors benefit from clearer volume sizing and fewer costly test failures. The programme is jointly administered by both organisations.

Erick Sharp, CEO, ACE Laboratories, said, “The rCB market has enormous potential, but growth has been held back by uncertainty about material quality and consistency. VericarbSM gives producers a way to prove their product and gives buyers the independent data they need to say yes.”

Dave Abdallah, Founder, Abdallah Consulting, said, “One key reason for the delayed growth of recovered carbon black is lack of product performance information in the customer’s language. ASTM standards are critical; in fact, most testing done in the process follows ASTM methods. But customers relate to a product better when its performance is shown in applications relevant to them. VericarbSM solves the language issue by showing verified rCB in terms of rubber performance while simultaneously adding credibility via third-party analysis and reporting.”

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